ATI Technologies Q46-85 O & M Manual
O & M Manual
Model Q46-85
Peracetic Acid Monitor
Home Office European Office
Analytical Technology, Inc. ATI (UK) Limited
6 Iron Bridge Drive Unit 1 & 2 Gatehead Business Park
Collegeville, PA 19426 Delph New Road, Delph
Phone: 800-959-0299 Saddleworth OL3 5DE
610-917-0991 Phone: +44 (0)1457-873-318
Fax: 610-917-0992 Fax: + 44 (0)1457-874-468
Email: sales@analyticaltechnology.com Email: sales@atiuk.com
Table of Contents
PART 1 - INTRODUCTION ................................. 4
1.1 General ...................................................... 4
1.2 Standard System ....................................... 5
1.3 Features ..................................................... 8
1.4 Q46/85 System Specifications .................. 9
1.5 Q46H Performance Specifications ...........10
PART 2 – ANALYZER MOUNTING .................11
2.1 General .....................................................11
2.2 Wall or Pipe Mount ..................................12
2.3 Panel Mounting ........................................14
PART 3 – SENSOR/FLOWCELL MOUNTING 15
3.1 General .....................................................15
3.2 Constant-Head Flowcell ...........................15
3.3 Sealed Flowcell ........................................16
3.4 Submersion Mounting ..............................18
PART 4 – ELECTRICAL INSTALLATION ......19
4.1 General .....................................................19
4.2 Power Connection ....................................19
4.4 Direct Sensor Connection ........................23
4.5 Sensor Wiring ......................................24
4.6 Junction Box Connection .........................25
PART 5 – SENSOR ASSEMBLY .........................26
5.1 PAA Sensor Preparation ..........................26
5.2 Optional pH Sensor ..................................28
PART 6 – CONFIGURATION .............................29
6.1 User Interface ...........................................29
6.11 Keys .........................................................30
6.12 Display .....................................................30
6.2 Software ...................................................32
6.21 Software Navigation ...............................32
6.22 Measure Menu [MEASURE] ...................35
6.23 Calibration Menu [CAL].............................36
6.24 Configuration Menu [CONFIG] ..............36
6.25 Control Menu [CONTROL] ....................41
6.26 Diagnostics Menu [DIAG] .........................45
PART 7 – CALIBRATION ...................................48
7.1 PAA Calibration ......................................48
7.11 PAA Zero Cal ..........................................48
7.12 PAA Span Cal ..........................................49
7.2 Temperature Calibration ..........................50
7.3 pH Calibration..........................................51
7.31 Two-Point pH Cal ....................................51
7.32 One-Point pH Cal .....................................52
PART 8 – PID CONTROLLER DETAILS .........53
8.1 PID Description .......................................53
8.2 PID Algorithm .........................................53
8.3 Classical PID Tuning ...............................55
8.4 Manual PID Override Control..................55
8.5 Common PID Pitfalls ...............................55
PART 9 – SYSTEM MAINTENANCE ................57
9.1 General .....................................................57
9.2 Analyzer Maintenance .............................57
9.3 PAA Sensor Maintenance ........................57
9.31 Sensor Acid Cleaning ..............................58
9.4 Flow Cell Maintenance ............................58
PART 10 – TROUBLESHOOTING ....................59
10.1 General .....................................................59
10.2 External Sources of Problems ..................59
10.3 Analyzer Tests .........................................60
10.4 Display Messages ....................................60
10.5 Sensor Tests .............................................63
SPARE PARTS ......................................................65
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Table of Figures
FIGURE 1 - TYPICAL SYSTEM DIAGRAM .......................................................................................... 5
FIGURE 2 - MONITORING SYSTEM W/BAYONET STYLE PH SNSOR .................................................... 6
FIGURE 3 - SEALED FLOWCELL ASSEMBLIES W/FLOW CONTROL ...................................................... 7
FIGURE 4 – Q46 ENCLOSURE DIMENSIONS .................................................................................. 11
FIGURE 5 - WALL OR PIPE MOUNT BRACKET ................................................................................. 12
FIGURE 6 - WALL MOUNTING DIAGRAM ........................................................................................ 13
FIGURE 7 - PIPE MOUNTING DIAGRAM .......................................................................................... 13
FIGURE 8 - PANEL MOUNT CUTOUT ............................................................................................. 14
FIGURE 9 - CONSTANT HEAD FLOWCELL DETAILS ......................................................................... 15
FIGURE 10 - SEALED FLOWCELL DETAILS ..................................................................................... 16
FIGURE 11 - SEALED PH FLOWCELL DETAILS ............................................................................... 17
FIGURE 12 - SUBMERSIBLE SENSOR MOUNTING ASSEMBLY .......................................................... 18
FIGURE 13 - LINE POWER CONNECTION ....................................................................................... 20
FIGURE 14 - OPTIONAL RELAY BOARD WIRING ............................................................................. 21
FIGURE 15 - OPTIONAL RELAY BOARD WIRING ............................................................................. 22
FIGURE 16 - OPTIONAL ANALOG OUTPUT WIRING ......................................................................... 22
FIGURE 17 - SENSOR CABLE PREPARATION ................................................................................. 23
FIGURE 18 - SENSOR WIRING ...................................................................................................... 24
FIGURE 19 - JUNCTION BOX INTERCONNECT WIRING .................................................................... 25
FIGURE 20 - PAA SENSOR ASSEMBLY ......................................................................................... 26
FIGURE 21 - SUBMERSIBLE PAA SENSOR ASSEMBLY ................................................................... 27
FIGURE 22 - USER INTERFACE ..................................................................................................... 29
FIGURE 23 - SOFTWARE MAP ...................................................................................................... 34
FIGURE 24 - AUTOMATIC PH BUFFER TABLES ............................................................................... 40
FIGURE 25 - CONTROL RELAY EXAMPLE, HYSTERSIS AND TWO OPPOSITE PHASE OPTIONS ............ 43
FIGURE 26 - ALARM RELAY EXAMPLE .......................................................................................... 44
FIGURE 27 - Q46H ISA (IDEAL) EQUATION ................................................................................... 53
FIGURE 28 - Q46H DSIAPLY MESSAGES ...................................................................................... 61
FIGURE 29 - DISPLAY MESSAGES (CONTINUED) ........................................................................... 62
FIGURE 30 - PT100 RTD TABLE .................................................................................................. 63
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Part 1 - Introduction
1.1 General
The Model Q46/85 is an on-line monitoring system designed for the continuous measurement of
Peracetic Acid (PAA) concentration in solution. The full scale operating range of the system may
be selected by the user for 0-20.00 ppm, 0-200.0 ppm, or 0-2000 ppm, and the sensing system
will operate on water streams with temperatures ranging from 0 to 50°C. The Q46/85 PAA
Measurement System is engineered for applications in which PAA is applied to water for
sterilization purposes
The basic sensing element used in the PAA monitor is a polarographic membrane sensor which
measures PAA directly. Water simply flows past the sensor and directly to drain, with the flow
rate and pressure across the sensor controlled by a constant head flow cell assembly. The PAA
measurement does not alter the sample or add any chemicals to the sample stream, so the water
flow can return to the system if desired.
Q46/85 Monitors are available in two basic electronic versions, a 90-260 VAC powered monitor,
or a 12-24 VDC powered monitor – both with three relays and two 4-20 mA analog outputs. Both
versions allow flexible output options which include additional 4-20 mA current outputs, additional
0-30 VDC signal relays, PID control, and digital communication cards.
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ATI Q46H/85 PAA System Part 2 – Analyzer Mounting
1.2 Standard System
The standard model Q46/85 system includes three main components, the Q46 analyzer, a
constant head flow cell, and a PAA sensor. A low-volume flowcell is also available for
applications where sample flowrate and pressure can be carefully controlled. Figure 1 shows a
typical installation including the optional pH sensor.
For connection of the sensor to the electronics, a 25' cable is supplied. An additional 100 feet of
interconnect cable may be added using #07-0100 junction box. All required spare parts are also
provided with the basic system, including spare membranes, electrolyte, o-rings, and any special
hardware.
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Figure 1 - Typical System Diagram
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ATI Q46H/85 PAA System Part 2 – Analyzer Mounting
Figure 2 below shows the same standard flowcell assembly and PAA sensor along with the
conventional type pH sensor. A special adapter is required to hold the pH sensor in its proper
location in the flowcell inlet chamber.
Figure 2 - Monitoring System w/Bayonet Style pH Snsor
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ATI Q46H/85 PAA System Part 2 – Analyzer Mounting
Figure 3 below shows an installation using a (00-1522) sealed flowcell for the PAA sensor and a (00-
1527) sealed flowcell for the pH sensor. This type of installation requires careful flow control. We
recommend the use of our (03-0371) flow control assembly when using sealed flowcells. This assembly
consists of an in-line filter and a fixed-flow regulator which will maintain a constant 400 cc/min flowrate
through the system. This flow will be maintained so long as inlet pressures are between 5 and 125 PSIG.
The in-line filter is used mainly to protect the flow control element against larger particles that might cause
plugging of the device.
Figure 3 - Sealed Flowcell Assemblies w/Flow Control
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1.3 Features
• Standard Q46H Analyzers have fully inputs and outputs. Analog outputs are additionally
completely isolated from each other
• Available in either 90-260 VAC or 12-24 VDC power supply systems. All features remain the
same in both variations.
• Output Hold, Output Simulate, Output Alarm, and Output Delay Functions. All forced changes in
output condition include bumpless transfer to provide gradual return to on-line signal levels and to
avoid system control shocks on both analog outputs.
• Three 6 amp SPDT relay outputs and two analog 4-20 mA outputs are standard. Software
settings for relay control include setpoint, deadband, phase, delay, and failsafe. An optional 3relay card for low voltage signals is available to bring the total to 6 relays.
• Selectable PID controller on main analog output. PID controller can operate with instrument
configured as loop-power transmitter, or as one of the two outputs on the AC powered instrument.
PID includes manual operation feature, and diagnostic “stuck-controller” timer feature for relay
notification of control problems.
• Two analog outputs on the relay version may be configured to track PAA and temperature, PAA
and PAA, or PAA and pH. Both analog outputs can be individually programmed to fail to specific
values.
• Digital communication option for Profibus-DP, Modbus-RTU, or Ethernet-IP. See Q46 Digital
Communications Manual for Specifications.
• Diagnostic messages provide a clear description of any problem with no confusing error codes to
look up. Messages are also included for diagnosing calibration problems.
• Quick and easy one-point calibration method and sensor zero-cal. To provide high accuracy, all
calibration methods include stability monitors that check temperature and main parameter stability
before accepting data.
• Security lock feature to prevent unauthorized tampering with transmitter settings. All settings can
be viewed while locked, but they cannot be changed.
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ATI Q46H/85 PAA System Part 2 – Analyzer Mounting
1.4 Q46/85 System Specifications
Displayed Parameters Main input, 0.01 ppm to 2000 ppm
Sensor temperature, -10.0 to 55.0 °C (23 to 131 ºF)
Sensor Current, 0.0–999.9 nA, 0.000 to 99.99 uA
Loop current, 4.00 to 20.00 mA
Sensor slope/offset
Model number and software version
PID Controller Status
Optional pH Input value. 0.00 to 14.00 pH
Main Parameter Ranges Manual selection of one of the following ranges,
0.00 to 20.00 ppm
0.0 to 200.0 ppm
0 to 2000 ppm
Display 0.75” (19.1 mm) high 4-digit main display with sign
12-digit secondary display, 0.3" (7.6 mm) 5x7 dot matrix.
Integral LED back-light for visibility in the dark.
Weight Approximately 5 lbs. (2.3 Kg) with sensor & flowcell
Ambient Temperature Analyzer Service, -20 to 60 °C (-4 to 140 ºF)
Sensor Service, -5 to 55°C (23 to 131 °F)
Ambient Humidity 0 to 95%, non-condensing
EMI/RFI Influence Designed to EN 61326-1, CE Marked
Output Isolation 600 V galvanic isolation
Filter Adjustable 0-9.9 minutes additional damping to 90% step input
Temperature Input Pt100 RTD with automatic compensation
Sensor 2-electrode polarographic membrane sensor for direct
Sensor Materials PVC and PEEK
Electrical Certification Ordinary Location, cCSAus (CSA and UL standards - both CSA
Sensor Cable 25 ft. (7.5 meter) cable with 6-pin plug.
Max. Sensor-to-Analyzer 100 feet (30.5 meters), with junction box
Distance
Flow Cell Constant head overflow, clear cast acrylic, 7-30 GPH, 15 GPH
Storage, -5 to 70 °C (-22 to 158 ºF)
measurement of PAA,
approved), pollution degree 2, installation category 2
recommended, inlet is ¼” hose barb at 1/8” MNPT, outlet is ½”
hose barb at 3/8” MNPT
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ATI Q46H/85 PAA System Part 2 – Analyzer Mounting
Power 90 - 260 VAC, 50-60 Hz, 10 VA max or
12-24 VDC, 500 mA max.
Enclosure NEMA 4X (IP-66), polycarbonate, stainless steel hardware,
weatherproof and corrosion resistant,
Mounting Options Wall or pipe mount bracket standard. Bracket suitable for either
1.5” or 2” I.D. U-Bolts for pipe mounting.
Panel mount adapter optional.
Conduit Openings Five ½” NPT openings, Adapter can be removed to provide a 1”
NPT opening in the bottom of the enclosure. Gland seals
provided but not installed.
Relays, Electromechanical: Three SPDT, 6 amp @ 250 VAC, 5 amp @ 24 VDC contacts.
Software selection for setpoint, phase, delay, deadband, hi-lo
alarm, and failsafe. A-B indicators on main LCD, and C indicator
on lower display.
Optional Relays: Three additional non-isolated low power relays available. SPST,
1 Amp @ 30 VDC.
Analog Outputs Two 4-20 mA outputs. Output one programmable for PPM PAA
or PID. Output 2 programmable for PPM PAA or Temperature.
Max load 500 Ohms for each output. Outputs ground isolated
and isolated from each other. An additional 3rd analog option is
available.
1.5 Q46H Performance Specifications
Accuracy 0.5% of selected range or 0.02 PPM
Repeatability 0.3% of selected range or 0.01 PPM
Sensitivity 0.05% of selected range
Non-linearity 0.1% of selected range
Warm-up Time 3 seconds to rated performance (electronics only)
Supply Voltage Effects ± 0.05% span
Instrument Response Time 60 seconds to 90% of step input at lowest damping
Equipment bearing this marking may not be discarded by traditional methods
in the European community after August 12 2005 per EU Directive
2002/96/EC. End users must return old equipment to the manufacturer for
proper disposal.
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ATI Q46H/85 PAA System Part 2 – Analyzer Mounting
Part 2 – Analyzer Mounting
2.1 General
All Q46 Series instruments offer maximum mounting flexibility. A bracket is included with each
unit that allows mounting to walls or pipes. In all cases, choose a location that is readily
accessible for calibrations. Also consider that it may be necessary to utilize a location where
solutions can be used during the calibration process. To take full advantage of the high contrast
display, mount the instrument in a location where the display can be viewed from various angles
and long distances.
Locate the instrument in close proximity to the point of sensor installation - this will allow easy
access during calibration. The sensor-to-instrument distance should not exceed 100 feet. To
maximize signal-to-noise ratio however, work with the shortest sensor cable possible. The
standard cable length of the PAA sensor is 25 feet.
Due to the flexibility of the instrument design, some of the mounting features change based on
the configuration that was ordered. For example, the 2-wire transmitter version is different for the
115/230 VAC controller because the rear of the enclosure is much deeper when the AC powered
unit is used. In addition, the AC powered unit has an integrated panel mount flange requiring a
single cutout for flush mounting.
Figure 4 – Q46 Enclosure Dimensions
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2.2 Wall or Pipe Mount
A PVC mounting bracket with attachment screws is supplied with each transmitter as shown in
Figure 5. The multi-purpose bracket is attached to the rear of the enclosure using the four flat
head screws. The instrument is then attached to the wall using the four outer mounting holes in
the bracket. These holes are slotted to accommodate two sizes of u-bolt that may be used to
pipe mount the unit. Slots will accommodate u-bolts designed for 1½ “ or 2” pipe. The actual
center to center dimensions for the u-bolts are shown in the drawing. Note that these slots are for
u-bolts with ¼-20 threads. The 1½” pipe u-bolt (2” I.D. clearance) is available from ATI in type
304 stainless steel under part number (47-0005).
Figure 5 - Wall or Pipe mount Bracket
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Figure 6 - Wall Mounting Diagram
Figure 7 - Pipe Mounting Diagram
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2.3 Panel Mounting
Panel mounting uses the panel mounting flange molded into the rear section of the enclosure.
Figure 8 provides dimensions for the panel cutout required for mounting.
The panel mounting bracket kit must be ordered separately (part number 05-0094). This kit
contains a metal retainer bracket that attaches to the rear of the enclosure, 4 screws for
attachment of this bracket, and a sealing gasket to insure that the panel mounted monitor
provides a water tight seal when mounted to a panel.
The sealing gasket must first be attached to the enclosure. The gasket contains an adhesive on
one side so that it remains in place on the enclosure. Remove the protective paper from the
adhesive side of the gasket and slide the gasket over the back of the enclosure so that the
adhesive side lines up with the back of the enclosure flange. Once in place, you can proceed to
mount the monitor in the panel.
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Figure 8 - Panel Mount Cutout
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Part 3 – Sensor/Flowcell Mounting
3.1 General
Select a location within the maximum sensor cable length for mounting of the sensor flow cell.
3.2 Constant-Head Flowcell
PAA sensors are best used in a constant-head overflow chamber because variations in sample
flow rate and pressure can cause unstable readings. When monitoring low concentrations (below
0.5 PPM), this method should always be used. Mechanical installation of the flow cell requires
that it be mounted to a wall or other convenient flat surface. Alternatively, the mounting holes on
the plate will accommodate a 2" U-bolt for mounting the plate to a 2" pipe. Figure 9 shows the
dimensions and mounting hole locations for the flow cell. Be sure to allow enough clearance on
the left side of the flow cell for insertion and removal of the sensor. About 12 inches clearance is
recommended.
Once mounted, inlet and drain connections must be made. The flow cell contains a 1/8" MNPT
inlet connection and a 3/8" MNPT drain connection. Hose barbs for the inlet and drain
connections are supplied with the flow cell for use with flexible tubing. The inlet hose barb is
used with ¼" I.D. tubing and the drain hose barb is used with ½" I.D. tubing.
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Figure 9 - Constant Head Flowcell Details
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ATI Q46H/85 PAA System Part 3 – Sensor/Flowcell Mounting
3.3 Sealed Flowcell
Applications where the sample inlet flow is well controlled can use a simpler sealed flowcell.
Using this flowcell requires that flow be controlled externally to about 400 cc/min. Variable flow
rate or variable pressure will cause unstable readings in this flowcell. ATI offers a special flow
control element that can be used ahead of this flowcell on the incoming sample line. The flow
control is part no. (55-0048). It will control the inlet flowrate at 400 cc/min. with inlet pressure
variations from 5-150 PSIG. A 50 micron y-strainer ahead of the flow control element is
recommended. The sealed flowcell provides a drain vent with check valve to avoid pulling a
vacuum on the flow chamber.
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Figure 10 - Sealed Flowcell Details
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ATI Q46H/85 PAA System Part 3 – Sensor/Flowcell Mounting
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Figure 11 - Sealed pH Flowcell Details
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ATI Q46H/85 PAA System Part 3 – Sensor/Flowcell Mounting
3.4 Submersion Mounting
Some applications are much easier done using the submersible sensor. This method can
sometimes be used where flow is reasonably constant, and hydraulic head does not vary
appreciably. PAA sensors can never be used in completely stagnant conditions. A flow velocity
of at least 0.3 feet per second is normally required for measurement. Any applications for a
submersible PAA sensor should first be discussed with ATI. A trial of such installations may be
necessary.
Submersible sensors are mounted to a 1" pipe using a standard 1" PVC thread by thread pipe
coupling. The mounting pipe can be secured to standard 1½" pipe rail using a mounting bracket
kit available from ATI (part number 00-0628) as shown in Figure 12 - Submersible Sensor Mounting
Assembly
.
SENSOR CABLE
2" HANDRAIL
SWIVEL MOUNTING BRACKET WITH
HARDWARE, SUPPLIED BY ATI
SUPPLIED BY ATI
SENSOR, TYPICAL
2 - 3 FT. SUBMERGENCE
1" ALUMINUM CONDUIT, THREADED1" T x T PVC COUPLING
ONE END OR 1" SCHED 80 PVC PIPE
LENGTH AS REQUIRED
(SUPPLIED BY CUSTOMER)
Figure 12 - Submersible Sensor Mounting Assembly
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Part 4 – Electrical Installation
4.1 General
The Q46 is powered in one of two ways, depending on the version purchased. The 12-24 VDC
powered analyzer requires a customer supplied DC power supply. The 90-260 VAC version
requires line power. Please verify the type of unit before connecting any power.
WARNING: Do not connect AC line power to a DC powered unit. Severe damage will
result.
Important Notes:
1. Use wiring practices that conform to all national, state and local electrical codes.
For proper safety as well as stable measuring performance, it is important that the
earth ground connection be made to a solid ground point from TB7. The AC power
supply contains a single 630mA slo-blo fuse (Wickmann/Littlefuse #372-0630). The
fuse F1 is located adjacent to TB7 and is easily replaceable.
2. Do NOT run sensor cables or instrument 4-20 mA output wiring in the same
conduit that contains AC power wiring. AC power wiring should be run in a
dedicated conduit to prevent electrical noise from coupling with the instrumentation
signals.
3. This analyzer must be installed by specifically trained personnel in accordance with
relevant local codes and instructions contained in this operating manual. Observe
the analyzer's technical specifications and input ratings. Proper electrical
disconnection means must be provided prior to the electrical power connected to
this instrument, such as a circuit breaker - rated 250 VAC, 2 A minimum. If one
line of the line power mains is not neutral, use a double-pole mains switch to
disconnect the analyzer.
4. Repeated problems with lightning strikes damaging sensitive instrumentation are
often attributed to poorly bonded earth grounds in the instrument power source. The
protection schemes incorporated into this analyzer cannot operate to maximum
efficiency unless the ground connection is at its’ absolute lowest impedance.
There is no standard ground resistance universally recognized. Many agencies
recommend a ground resistance value of 5 ohms or less. The NEC recommends an
impedance to ground of less than 25 ohms, and less than 5 ohms where sensitive
equipment is installed. Power sources feeding sensitive instruments like the
Q46H/79PR should have the lowest possible impedance to ground.
4.2 Power Connection
Verify the AC power supply requirement before installing. Also verify that power is fully
disconnected before attempting to wire.
Q46 systems are supplied with 5 cable gland fittings for sealing cable entries.
Connect HOT, NEUTRAL, and GROUND to the matching designations on terminal strip TB7.
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ATI Q46H/85 PAA System Part 4 – Electrical Installation
WARNING
Disconnect line power voltage BEFORE connecting
line power wires to Terminal TB7 of the power supply.
wire
ies are
260 VAC operation at the factory at
time of order, and the power supply is labeled as
such. Do NOT connect voltages other than the
The two analog outputs for the standard system are present at terminalTB1. The loop-load
limitation in this configuration is 500 Ohms maximum for each output. Also note that these two
outputs are completely isolated from each other to insure that ground loops do not result from the
connection of both outputs to the same device such as a PLC or DCS.
A ribbon cable connects the power supply assembly with the microprocessor assembly located in
the front section of the enclosure. This cable may be unplugged from the front section of the
monitor if service is needed, but should normally be left in place during installation.
The power supply accepts only standard threesingle phase power. AC power suppl
configured for 90-
labeled requirement to the input.
Figure 13 - Line Power Connection
The power strip, TB7, allows up to 12 AWG wire. A wire gauge of 16 AWG is recommended to
allow for an easy pass-through into the ½” NPT ports when wiring.
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4.3 Relay Connection
Three SPDT relays are provided on the power supply board. None of the relay contacts are
powered. The user must supply the proper power to the contacts. For applications that require
the same switched operating voltage as the Q46 (115 or 230 V), power may be jumpered from
the power input terminals at TB7. Relay wiring is connected at TB4, TB5, and TB6 as shown
below. Note that the relay contact markings are shown in the NORMAL mode. Programming a
relay for “Failsafe” operation reverses the NO and NC positions in this diagram
Figure 14.
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Figure 14 - Optional Relay Board Wiring
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